Maximize Efficiency and Profitability with a Scales Three-Tiered Compressed Air System Analysis

Who in their right mind would hire a large bus to drive a single person to the mall or cook up 20 pounds of pasta to feed a family of four? Yet every day many manufacturing facilities consume and pay for more energy than they need to run production. As a result they drastically reduce profitability and their competitive edge.

Scales Industrial Technologies' compressed air systems assessment team has seen this kind of inefficiency on a regular basis. This is why Scales has formulated its three-tier compressed air systems assessment process to help customers regulate their power consumption and better meet their actual operating requirements.

"The first step in analyzing the efficiency of a compressed air system is a walk-through evaluation," explains Scales' Systems Engineer, Steve Lichtenstein. Customers are typically surprised at what this relatively simple procedure can uncover; almost as much as they are when first told Scales offers walk-through evaluations at no charge. "While this process is not meant to provide a highly-detailed analysis, it enables us to identify significant reductions in energy usage, as high as 25 percent. It also reveals ways we can lower a customer's maintenance costs. Once the initial walk-through is completed and savings opportunities are identified, we then determine if a more comprehensive analysis is beneficial."

If the walk-through identifies critical issues that require additional investigation and data to formulate a solution, a Compressed Air System Assessment or a Comprehensive Compressed Air Audit would be conducted by the Scales team.

A Compressed Air Assessment combines available data with limited measurements at carefully chosen locations to identify system dynamics along with a compressed air block diagram. In addition, potentially inappropriate uses of compressed air are highlighted with alternative options.

A Compressed Air Audit includes the steps as outlined above and data logging of system-wide readings over a period of time, including system pressure, compressed air demand and kilowatt. A comprehensive profile of supply and demand is developed along with recommendations to reduce compressed air demand, energy consumption and improve system reliability.

Both of these evaluations allow Scales to establish a baseline against which the results of the team's proposed changes are precisely measured. An assessment usually takes two-to-five days to complete; comprehensive audits three-to-ten days.

One of many customers that have realized significant energy cost savings from a Scales analysis is Strategic Content Imaging of Secaucus, New Jersey. A no-charge Scales walk-through revealed that a much larger compressor was being used than required to meet the plant's compressed air demand. "After discussing present and future requirements with management, the solution was clear", says Lichtenstein. "Although their plant's compressed air demand has been reduced in recent years, Strategic Content Imaging was still utilizing a large 200-horsepower air compressor. The compressor operates more than 6,000 hours a year and the high electrical energy cost was a drain on Strategic Content Imaging's bottom line".

Lichtenstein continues, "Our walk-through confirmed Strategic Content Imaging's new requirements could be met by replacing the current 200-hp air compressor package with a 50-hp variable speed drive model resulting in a power reduction of approximately 100kW. This calculates to approximately $75,000 in annual energy cost savings. Most importantly, Strategic Content Imaging's production levels were not adversely affected". Whoever coined the phrase 'less is more' must have had them in mind.

Scales guarantees your satisfaction with all its services. The sooner you call, the quicker you'll start saving. Remember...the walk-through assessment costs nothing, so all you can lose is the continued wasting of energy and money.